Methods for doping fin field-effect transistors

ABSTRACT

A method of doping a FinFET includes forming a semiconductor fin on a substrate, the substrate having a first device region and a second device region. The semiconductor fin is formed on a surface of the substrate in the second device region and has a top surface and sidewalls. The first device region is covered with a hard mask and the semiconductor fin and the hard mask are exposed to a deposition process to form a dopant-rich layer having an n-type or p-type dopant on the top surface and the sidewalls of the semiconductor fin. The dopant from the dopant-rich layer is diffused into the semiconductor fin by performing an annealing process in which the first device region is free of diffusion of the diffused dopant or another dopant from the hard mask.

PRIORITY CLAIM

The present application is a continuation of U.S. application Ser. No. 12/768,884, filed Apr. 28, 2010, which is incorporated herein by reference in its entirety.

RELATED APPLICATIONS

The present application is related to U.S. patent application Ser. No. 12/707,788, filed on Feb. 18, 2010, titled MEMORY POWER GATING CIRCUIT AND METHODS; Ser. No. 12/758,426, filed on Apr. 12, 2010, titled FINFETS AND METHODS FOR FORMING THE SAME; Ser. No. 12/731,325, filed on Mar. 25, 2010, titled ELECTRICAL FUSE AND RELATED APPLICATIONS; Ser. No. 12/724,556, filed on Mar. 16, 2010, titled ELECTRICAL ANTI-FUSE AND RELATED APPLICATIONS; Ser. No. 12/757,203, filed on Apr. 9, 2010, titled STI STRUCTURE AND METHOD OF FORMING BOTTOM VOID IN SAME; Ser. No. 12/797,839, filed on Jun. 10, 2010, titled FIN STRUCTURE FOR HIGH MOBILITY MULTIPLE-GATE TRANSISTOR; Ser. No. 12/831,842, filed on Jul. 7, 2010, titled METHOD FOR FORMING HIGH GERMANIUM CONCENTRATION SiGe STRESSOR; Ser. No. 12/761,686, filed on Apr. 16, 2010, titled FINFETS AND METHODS FOR FORMING THE SAME; Ser. No. 12/766,233, filed on Apr. 23, 2010, titled FIN FIELD EFFECT TRANSISTOR; Ser. No. 12/757,271, filed on Apr. 9, 2010, titled ACCUMULATION TYPE FINFET, CIRCUITS AND FABRICATION METHOD THEREOF; Ser. No. 12/694,846, filed on Jan. 27, 2010, titled INTEGRATED CIRCUITS AND METHODS FOR FORMING THE SAME; Ser. No. 12/638,958, filed on Dec. 14, 2009, titled METHOD OF CONTROLLING GATE THICKNESS IN FORMING FINFET DEVICES; Ser. No. 12/768,884, filed on Apr. 28, 2010, titled METHODS FOR DOPING FIN FIELD-EFFECT TRANSISTORS; Ser. No. 12/731,411, filed on Mar. 25, 2010, titled INTEGRATED CIRCUIT INCLUDING FINFETS AND METHODS FOR FORMING THE SAME; Ser. No. 12/775,006, filed on May 6, 2010, titled METHOD FOR FABRICATING A STRAINED STRUCTURE; Ser. No. 12/886,713, filed Sep. 21, 2010, titled METHOD OF FORMING INTEGRATED CIRCUITS; Ser. No. 12/941,509, filed Nov. 8, 2010, titled MECHANISMS FOR FORMING ULTRA SHALLOW JUNCTION; Ser. No. 12/900,626, filed Oct. 8, 2010, titled TRANSISTOR HAVING NOTCHED FIN STRUCTURE AND METHOD OF MAKING THE SAME; Ser. No. 12/903,712, filed Oct. 13, 2010, titled FINFET AND METHOD OF FABRICATING THE SAME; 61/412,846, filed Nov. 12, 2010, 61/394,418, filed Oct. 19, 2010, titled METHODS OF FORMING GATE DIELECTRIC MATERIAL and 61/405,858, filed Oct. 22, 2010, titled METHODS OF FORMING SEMICONDUCTOR DEVICES.

TECHNICAL FIELD

The disclosure relates generally to integrated circuit devices, and more particularly to methods for doping fin field-effect transistors (FinFETs).

BACKGROUND

In the rapidly advancing semiconductor manufacturing industry, complementary metal oxide semiconductor (CMOS) FinFET devices may be used in many logic and other applications and are integrated into various different types of semiconductor devices. FinFET devices typically include semiconductor fins with high aspect ratios in which the channel and source/drain regions for the transistor are formed. A gate is formed over and along the sides of the portion of the fin devices utilizing the advantage of the increased surface area of the channel and source/drain regions to produce faster, more reliable and better-controlled semiconductor transistor devices. Further advantages of FinFETs include reducing the short channel effect and higher current flow.

Current FinFET technology has challenges however. For example, ion implantation is typically used to form a lightly doped drain (LDD) region. Ion implantation creates a non-conformal doping profile of the fin (for example, heavier doping at the top of the fin than the bottom of the fin, which is found closer to the substrate). This non-conformal doping profile may create issues including those associated non-uniform device turn on. By using a tilt implant, the photo resist height induced shadowing effects and pre amorphization (PAI) induced twin boundary defects will be disadvantageous.

As such, an improved fabrication method for a FinFET element is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIGS. 1 to 8 show various stages during fabrication of a FinFET structure on a substrate according to one or more embodiments.

FIG. 9 illustrates an apparatus for performing method in accordance with an embodiment.

FIG. 10 shows schematic DC and RF bias voltages applied during the deposition of a dopant-rich layer.

FIG. 11 depicts a flowchart of a method for fabricating FinFET structures according to one embodiment.

DETAILED DESCRIPTION

The making and using of illustrative embodiments are discussed in detail below. It should be appreciated, however, that the disclosure provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative and do not limit the scope of the invention.

FIGS. 1 to 8 are perspective and cross-sectional views of FinFET structure at various stages of manufacture. FIG. 11 depicts a flowchart of a method 1100 for fabricating FinFET structures according to one embodiment of the invention.

Referring to FIG. 1 and FIG. 11, in process step 201, a substrate comprising a first fin 105 and a second fin 107 is provided. In some embodiments, substrate 101 may be a silicon substrate, a germanium substrate, or a substrate formed of other semiconductor materials. Substrate 101 may be doped with a p-type or an n-type dopant. Isolation regions such as shallow trench isolation (STI) regions 103 may be formed in or over substrate 101. The first semiconductor fin 105 and the second semiconductor fin 107 extend above the top surfaces of STI regions 103. The first semiconductor fin 105 has a top surface 111 and sidewalls 109. The second semiconductor fin 107 has a top surface 115 and sidewalls 113. Substrate 101 includes a portion in first device region 100 and a portion in second device region 200. Semiconductor fins 105 and 107 are in first device region 100 and second device region 200, respectively. In an embodiment, first device region 100 and second device region 200 are used to form one n-type FinFET and one p-type FinFET.

Referring to FIG. 2, gate dielectric layer 117 and gate electrode layer 119 are deposited in both first device region 100 and second device region 200 and over semiconductor fins 105 and 107. In an embodiment, gate dielectric layer 117 is formed of a high dielectric constant (high-k) dielectric material. The exemplary high-k materials may have k values greater than about 4.0, or even greater than about 7.0, and may include aluminum-containing dielectrics such as Al₂O₃, HfAlO, HfAlON, or AlZrO; Hf-containing materials such as HfO₂, HfSiO_(x), HfAlO_(x), HfZrSiO_(x), or HfSiON; and/or other materials such as LaAlO₃ or ZrO₂. Gate electrode layer 119 is formed on gate dielectric layer 117, and may be formed of a conductive material such as doped polysilicon, metals, or metal nitrides.

Referring to FIG. 3 and FIG. 11, in process step 203, gate electrode layer 119 and gate dielectric layer 117 are then patterned to form gate stacks. The gate stack in first device region 100 includes gate electrode 123 and gate dielectric 121. The gate stack in second device region 200 includes gate electrode 127 and gate dielectric 125. The gate stacks are over a portion of the top surfaces 111, 115 and the sidewalls 109, 113 of each of the semiconductor fins 105 and 107. In some embodiments, the exposed portions of semiconductor fins 105 and 107 may be left as they are, so that subsequent pocket and lightly doped source and drain (LDD) regions may be formed. In some alternative embodiments, the exposed portions of semiconductor fins 105 and 107 may be removed to form recesses, and semiconductor stressors may be epitaxially re-grown in the resulting recesses. In an exemplary embodiment, the semiconductor stressors in first device region 100 may comprise silicon carbon (SiC), while the semiconductor stressors in second device region 200 may comprise silicon germanium (SiGe)

Referring to FIG. 4 and FIG. 11, in process step 205, hard mask 129 is formed and patterned to cover the first device region 100, while leaving the second device region 200 uncovered. FIG. 4 is a cross-sectional view obtained from the vertical plane crossing line A-A′ in FIG. 3. Accordingly, the gate stacks are not shown.

Referring to FIG. 11, in process step 207, the process step 207 removes a native oxide layer on the exposed portion of the top surfaces 111, 115 and the sidewalls 109, 113 of each semiconductor fins 105 and 107. In one embodiment, the substrate 101 is dipped in a solution comprising a HF solution, which is diluted at a rate of 350:1. In another embodiment, the wet solution comprises any suitable solution being familiar to the skilled persons in the art. In some embodiments, the process step 207 comprises dry etching process being familiar to the skilled persons in the art.

Referring to FIG. 5, wafer 10 is placed into apparatus 300 as shown in FIG. 9, which is used for performing a plasma assisted deposition process. Apparatus 300 includes chamber 302, in which wafer 10 is placed, and power sources 304 and 306 connected into chamber 302. Wafer 10 comprises the semiconductor fins 105 and 107 on the substrate 101. Power source 304 may be a radio frequency (RF) power source with programmable pulse modulation function, while power source 306 may be a pulsed DC or RF power source for providing a bias voltage on the wafer 10. Power sources 304 and 306 may be operated independently from each other. Each of the power sources 304 and 306 may be programmed to be independently powered on and off without affecting the other.

Referring to FIG. 5 and FIG. 11, in process step 209, dopant-rich layer 131 is deposited on the top surface 115 and the sidewalls 113 of the second semiconductor fin 107 using production tool 300 as illustrated in FIG. 9. The dopant-rich layer 131 comprises a dopant that is used for forming the desirable LDD regions in the second semiconductor fin 107. Depending on the desirable conductivity type of the resulting FinFET, dopant-rich layer 131 may be formed of an n-type dopant (impurities) or a p-type dopant (impurities). For example, if the resulting FinFET is a p-type FinFET, dopant-rich layer 131 may comprise boron and/or indium, while if the resulting FinFET is an n-type FinFET, dopant-rich layer 131 may comprise phosphorous and/or arsenic. In an exemplary embodiment, the atomic percentage of the desirable dopant in dopant-rich layer 131 may be greater than about 90 percent, and may actually be a pure dopant layer.

The process gases in chamber 302 (refer to FIG. 9) may include AsH₃, B₂H₆, PH₃, BF₃, dilution gas such as Xe, Ar, He, Ne, H2 and/or the like, depending on the desirable composition of dopant-rich layer 131. The process may be performed under a pressure less than about 100 mTorr. RF power source 304 (FIG. 9) is turned on to generate plasma 308. The power of RF power source 304 may be between about 50 watts and about 1,000 watts, for example, although a greater or a smaller power may also be used. In an embodiment, RF power source 304 is turned on continuously during the entire period for forming dopant-rich layer 131. In an alternative embodiment, RF power source 304 is pulsed (in an on and off pattern) in order to improve the conformity (the step coverage) of dopant-rich layer 131.

During the formation of dopant-rich layer 131, DC power source 306 as in FIG. 9 has a low bias voltage lower than about 2 kV so that there is no unwanted amorphization layer formation during dopant layer formation. In an exemplary embodiment, the bias voltage output of DC power source 306 is between about 0 kV and about 2 kV. With the low or even zero DC bias voltage, the directionality of the ion doping process is reduced, and hence dopant-rich layer 131 may be deposited over the second semiconductor fin 107 as a separate layer, rather being directly implanted into fin 107. The DC bias voltage provided by DC power source 306 during the formation of dopant-rich layer 131 may also be pulsed (turned on and off) with a frequency of about 0.5 to about 10 KHz, as schematically illustrated in FIG. 10.

Referring to FIG. 6 and FIG. 11, in process step 211, a cap layer 133 is then deposited over the dopant-rich layer 131 on the second semiconductor fin 107. In some embodiments, the cap layer 133 may include silicon oxide, silicon nitride, silicon carbide or combinations thereof. The cap layer 133 has a thickness between about 30 Å to about 300 Å. Depending on cap layer 133 film density and compactness, the thickness of cap layer 133 should be controlled within a proper range. For example, in some embodiments, when the thickness is thinner than about 30 Å, the dopant in the dopant-rich layer 131 will diffuse out through the cap layer 133 during the following annealing process; when the thickness is thicker than about 300 Å, the cap layer 133 may peel off from the dopant-rich layer 131.

In one embodiment, the cap layer 133 is formed using plasma enhanced atomic layer deposition. Process precursor may include silanediamine, N, N, N′, N′-tetraethyl (sold as SAM 24 by Air Liquide) and O2. An operation power of the deposition is about 20 W to about 500 W. The cap layer 133 is formed at a temperature below about 300° C. to prevent the dopant in the dopant-rich layer 131 from diffusing out through the cap layer 133 during the cap layer formation process. In some alternative embodiments, the cap layer 133 may be deposited using other deposition techniques capable of forming a conformal layer of SiO₂, Si₃N₄, or SiC.

Referring to FIG. 7 and FIG. 11, in process step 212, the substrate 101 is annealed to form a LDD region 137 in the second semiconductor fin 107. The impurities in the dopant-rich layer 131 are activated and diffuse into the second semiconductor fin 107. The cap layer 133 prevents the dopant in the dopant-rich layer 131 from diffuse out through the cap layer 133 during the annealing process. The annealing may be performed at a wafer temperature between about 900° C. and about 1100° C. The annealing may be a millisecond annealing (MSA) or a rapid thermal annealing (RTA).

Next, in FIG. 11 of process step 213, the hard mask layer 129 in the first device region 100 is removed. Referring to FIG. 11, in process step 215, the cap layer 133 and the dopant-rich layer 131 are removed. In one embodiment, the process step 215 comprises dipping the substrate 101 in a wet solution comprising HF. In some embodiments, the process step 215 comprises etching the cap layer 133 and the dopant-rich layer 131 by a dry etching process.

FIG. 8 shows a substrate comprising a first fin 105 and a second fin 107 have LDD region 135 and LDD region 137 respectively. The LDD region 135 may be formed in the first semiconductor fin 105 using essentially the same process as discussed, except the second semiconductor fin 107 is covered by a hard mask during the formation of LDD region 137, and the first semiconductor fin 105 may have an opposite conductivity type than the second semiconductor fin 107. The dopant concentration in LDD regions may be between about 1E20/cm³ and about 1E21E/cm³, for example.

After the formation of LDD regions 135 and 137, gate spacers (not shown) may be formed. In subsequent process steps, n-type impurities (such as phosphorous) and p-type impurities (such as boron) may be implanted into fins 105 and 107, depending on the desirable conductivity types, to form deep source and drain regions (not shown). The dopant concentration in deep source/drain regions (not shown) may be between about 1×10²⁰/cm³ and about 1×10²¹/cm³, for example. FinFETs in the first device region 100 and the second device region 200 are thus formed.

FIGS. 1-11 are simplified for a better understanding of the inventive concepts of the present disclosure. For example, although the figures illustrate the FINFETs, it is understood the ICs may also include a number of various devices including resistors, capacitors, inductors, fuses, etc.

Various embodiments of the present invention may be used to moderate the shortcomings of the conventional LDD process. For example, in the various embodiments the formation of dopant-rich layer 131, the formation of cap layer 133 and the annealing process drive the impurities of the LDD region to a desirable depth without the concern of the shadowing effect and PAI induced twin boundary defects. Therefore, electrical performances of the devices can be improved.

In some embodiments, a method of doping a FinFET comprises forming a semiconductor fin on a substrate, the substrate comprising a first device region and a second device region. The semiconductor fin is formed on a surface of the substrate in the second device region and has a top surface and sidewalls. The method further comprises covering the first device region with a hard mask, exposing the semiconductor fin and the hard mask to a deposition process to form a dopant-rich layer comprising an n-type or p-type dopant on the top surface and the sidewalls of the semiconductor fin, and diffusing the dopant from the dopant-rich layer into the semiconductor fin by performing an annealing process. The first device region is free of diffusion of the diffused dopant or another dopant from the hard mask.

In some embodiments, a method of doping a FinFET comprises forming a hard mask that covers a first semiconductor fin of a substrate and leaves a second semiconductor fin of the substrate exposed, and applying a deposition process to the hard mask and the exposed second semiconductor fin to form a dopant-rich layer comprising an n-type or p-type dopant on a top surface and sidewalls of the second semiconductor fin. The method further comprises performing an annealing process to diffuse the dopant from the dopant-rich layer into the second semiconductor fin, wherein the first semiconductor fin is free of diffusion of the diffused dopant or another dopant from the hard mask.

In some embodiments, a method of doping a FinFET comprises, for each semiconductor fin of a first semiconductor fin of the FinFET and a second semiconductor fin of the FinFET, forming a hard mask that covers a portion of the FinFET and leaves the semiconductor fin exposed, depositing a dopant-rich layer comprising an n-type or p-type dopant directly on a top surface and sidewalls of the semiconductor fin, and performing an annealing process to drive the dopant from the dopant-rich layer into the semiconductor fin. The annealing is performed with the semiconductor fin uncovered by the hard mask and with the portion of the FinFET covered by the hard mask free of the dopant-rich layer, wherein the dopant from the dopant-rich layer is the only dopant diffused into the FinFET in the annealing process.

Although the embodiments and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. 

What is claimed:
 1. A method of doping a fin field-effect transistor (FinFET), the method comprising: forming a semiconductor fin on a substrate, the substrate comprising a first device region and a second device region, the semiconductor fin being formed on a surface of the substrate in the second device region, wherein the semiconductor fin has a top surface and sidewalls; covering the first device region with a hard mask; exposing the semiconductor fin and the hard mask to a deposition process to form a dopant-rich layer comprising an n-type or a p-type dopant on the top surface and the sidewalls of the semiconductor fin; diffusing the dopant from the dopant-rich layer into the semiconductor fin by performing an annealing process, wherein the first device region of the substrate is free of diffusion of the diffused dopant or another dopant from the hard mask; and forming a gate stack over a portion of the top surface and the sidewalls.
 2. The method of claim 1, wherein the deposition process forms the dopant-rich layer having atomic percentage of the dopant greater than 90 percent.
 3. The method of claim 1, wherein the deposition process comprises a plasma-assisted process.
 4. The method of claim 3, wherein the plasma-assisted process comprises biasing the substrate with a DC bias voltage less than 2 kV.
 5. The method of claim 1, wherein the deposition process forms the dopant-rich layer comprising the dopant including boron, indium, phosphorous or arsenic.
 6. The method of claim 1, further comprising removing a native oxide before exposing the semiconductor fin and the hard mask to the deposition process.
 7. The method of claim 1, wherein diffusing the dopant from the dopant-rich layer into the semiconductor fin forms a lightly-doped source/drain (LDD) region in the semiconductor fin.
 8. The method of claim 7, further comprising implanting impurity atoms in the semiconductor fin to form a deep source or drain region.
 9. The method of claim 1, further comprising using a cap layer over the dopant-rich layer to prevent outward diffusion of the dopant during the annealing process.
 10. The method of claim 1, further comprising removing the dopant-rich layer after diffusing the dopant from the dopant-rich layer into the semiconductor fin.
 11. A method of doping a fin field-effect transistor (FinFET), the method comprising: forming a hard mask that covers a first semiconductor fin of a substrate and leaves a second semiconductor fin of the substrate exposed; applying a deposition process to the hard mask and the exposed second semiconductor fin to form a dopant-rich layer comprising an n-type or a p-type dopant on a top surface and sidewalls of the second semiconductor fin; performing an annealing process to diffuse the dopant from the dopant-rich layer into the second semiconductor fin, wherein the first semiconductor fin is free of diffusion of the diffused dopant or another dopant from the hard mask; and forming a gate stack over a portion of the top surface and the sidewalls.
 12. The method of claim 11, wherein the deposition process forms the dopant-rich layer having atomic percentage of the dopant greater than 90 percent.
 13. The method of claim 11, wherein the deposition process comprises a plasma-assisted process.
 14. The method of claim 13, wherein the plasma-assisted process comprises biasing the substrate with a DC bias voltage less than 2 kV.
 15. The method of claim 11, wherein the deposition process forms the dopant-rich layer comprising the dopant including boron, indium, phosphorous or arsenic.
 16. The method of claim 11, further comprising removing a native oxide before applying the deposition process to the hard mask and the exposed second semiconductor fin.
 17. The method of claim 11, wherein diffusing the dopant from the dopant-rich layer into the second semiconductor fin forms a lightly-doped source/drain (LDD) region in the second semiconductor fin.
 18. The method of claim 11, further comprising using a cap layer over the dopant-rich layer to prevent outward diffusion of the dopant during the annealing process.
 19. A method of doping a fin field-effect transistor (FinFET), the method comprising, for each semiconductor fin of a first semiconductor fin of the FinFET and a second semiconductor fin of the FinFET: forming a hard mask that covers a portion of the FinFET and leaves the semiconductor fin exposed; depositing a dopant-rich layer comprising an n-type or a p-type dopant directly on a top surface and sidewalls of the semiconductor fin; performing an annealing process to drive the dopant from the dopant-rich layer into the semiconductor fin, the annealing being performed with the semiconductor fin uncovered by the hard mask and with the portion of the FinFET covered by the hard mask free of the dopant-rich layer, wherein the dopant from the dopant-rich layer is the only dopant diffused into the FinFET in the annealing process; and forming a gate stack over a portion of the top surface and the sidewalls.
 20. The method of claim 19, wherein depositing the dopant-rich layer comprises performing a plasma assisted deposition process. 